Detecting Rotor Bar Problems in

AC Induction Motors
by Airborne/Structureborne Ultrasound
Mechanical Inspection.
Mechanical Department.
Predictive Maintenance & Reliability
Speaker: Eng. Carlos Hdz. Conti, CMRP

Level II Airborne Ultrasound Certified Analyst. By UESystems

ClearWater Beach, F.L. Mayo 2011 1

Content
About TLA
Machine.
Problem.
Diagnostic Chart.
Failure Zone Graph.
Failure Effect.

Technique.
Recommendations & Diagnostics
Results.
References.
Appendix A, MCA Diagnostics &
Severity Chart.

TLA ALTAMIRA WHERE IS IT?

ORGANIZATIONAL STRUCTURE & PROCESS

Type

Joint Venture ( Shell-TotalMitsui )

Industry

Oil & Gas

Founded

2004, by Shell-Total-Mitsui

Headquarters Altamira, Tams. MX

Key people

Carlos Barajas (Managing

Director)
Loran Karwacki (Asset manager)
Jair Rojas (Finance Manager)
Carlos Oropeza (Operations
Manger)
Juan M. Hdz (Maintenance
Manager)
Vernica Zavaleta ( HR Manager)
Luis Nez (Commercial &
Proyects Manager)

Products

Natural Gas

Employees

80 (2010)

Website

http://www.shell.com/
http://www.altamiralng.com.mx

LNG Importing Terminal - Assets & Technical Scope.

Berthing basin, including mooring & unloading facilities for LNG
Carriers (Carrier Capacity 70,000 to 200,000 m3)
2 LNG Storage Tanks (net capacity 150,000 m3 each)
Process equipment for vaporization & gas pressurizing;
Seawater Supply System with capacity of up to 30,000 m3/hr
Send Out Facilities into Pemex Pipeline and Altamira V PP
Buildings (Control Room, Administration Building, Warehouse
2010 replacing temporary buildings)
Terminal Capacity (Phase 1): 760 mmscf/d Peak (500mmscfd
base load = 3.75 mtpa)
Potential for Expansion (Phase 2):1,200 mmscf/d Peak
(1070mmscfd base load = 8 mtpa)

Machine: PM-1501
PM-1501 is an electric motor of approximately 450 HP's and runs at 1800 rpm, is coupled to a double
suction bipartite horizontal centrifugal pump, whose function is to provide water for fire fighting, this
machine operates every week about 10 minutes and the route is inspected every 3 months.

Safe Maintenance
P-F Curve, Safety and Reliability
Where is safer, reliable and economic doing maintenance?

Source:
PdM Secrets Revealed 4th Ed AlliedcRealiaility
Are You Doing Too Much PM?

Problem:
PM1501, Ultrasound Spectrum Analysis shows a typical spectrum of Rotor Loose-Broken Bar Problems
in the engine, note Rotor Bar Pass Frec. @102.7 kcpm and up to 4 harmonics each one with
SideBands @ 2XFl. Bars # = 102700 cpm / 1800 rpm = 57.05 bars

Diagnostic Chart:

Diagnostic Chart:
A normal AC motor signature ought to include a rotor bar passing frequency
(RBPF) response. This response takes place when each rotor bar passes slight disruptions
within the magnetic field because of the electrical currents path through the stator/rotor
geometry. An elevated RBPF is created when the rotor bars pass a significant disruption in
these fields produced when the current path is altered or distorted from broken or cracked
rotor bars, loose or defective rotor bar joints, improperly brazed rotor bar joints, porous rotor
bar castings, or electrical arcing across the rotor bar to end ring interfaces.
RBPF is recognized as an integer multiple of rotor speed, and will usually have
sidebands spaced at 2x electrical line frequency (7200 CPM). Rotor eccentricity problems
can be indicated by additional (less dominant) sidebands sets spaced at 1x RPM.
AC motor may have from 35-96 rotor bars, so an FFT spectrum with
sufficient frequency range will be necessary to capture this fault. 1x and 2x RBPF will
be captured by a 360000 CPM with a 1600 FFT line resolution, and will provide enough
resolution to define the 2x LF sidebands.
Severity is usually judged by changes in RBPF amplitudes over time. Amplitude variation
with load is common.

10

Failure
Zone Graph:

11

Failure Effect:

When analyzing the

post mortem
rotor
failure, locate and
identify
points
of
blackened-blue
overheating
areas
Check dye penetrant
crack.

12

Failure Effect:

13

Technique:
The inspection technique used was: Mechanical inspection of bearings, using
magnetic module placed closest to the loading of the bearings, a freq. @ 25 kHz
was settled, the data was saved and downloaded to the DMS for follow-up. This
type of problems typically generate audible go & back sound .

14

Recommendation & Diagnostics:

Applying the Theory of Vibration Analysis to Ultrasound Analysis: When dealing
with Problems of Rotor Bar Loose / Broken in electric motors, their
physics is not due to friction or impact, and if not settled a Fmax. suitable
for capturing high frequencies in the FFT, they can go unnoticed, their
severity is dictated by the amount of harmonics, as well as side bands
around them, this is an advantage of using ultrasound in mechanical
inspections. For better results try to apply and combine diagnostics with
at least 2 PdM technologies. ( see appendix A)

Results:
It was proceeded to prepare the respective report, continuing with routine
monitoring, this type of rotor problems are usually related to manufacturing
quality problems, and given that the engine do not operates continuously, its
development has been slow, but by predictive task, this Potential Failure as
intensified so shall be changed with the spare motor, which is already in stock.

15

Appendix A MCA:
MCA results performed on this same engine to confirm the problem, note the
warning notice indicating possible failure of rotor bars.
Motor ID
Database
Building
Location
Date/Time

PM 1501 TLA
WORK 2005
Bba contraincendio
BASEMENT
4/14/2011 01:21:31 PM
Name Plate
450.00
1785
4160
55.0
1.0
1.0
1324.7
98.5
100.0

Hp
RPM
Volts
Amps
pf (pu)
Nema Derating (pu)
Torque (ft-lb)
Efficiency
Percent Load
Test
% Over Voltage
% Unbalance
% Voltage Dist.
% Current
Ef. Service Factor
Rotor Bar (db)
% Op. Point
% Loss Diff.
% Loss Diff.

Tested by
Tested for
Explorer SN#
Test Type

Value
2.43
0.75
0.57
71.33
0.73
-30.87
0.00
0.00
N/A

Status
GOOD
GOOD
GOOD
GOOD
GOOD
WARNING
GOOD
INDET
INDET

333
Electrical
Measured
326.72
1792.6
4261.3
38.6
0.9
1.0
957.7
96.4
72.6

Caution Level
10.0
2.0
7.0
110.0
1.1
-45.0
20.0
25.0
60.0

Warning Level
20.0
3.5
9.0
120.0
1.2
-36.0
30.0
50.0
24.0

16

Appendix A:
MCA
Power Spectrum
Graphics showing
the Rotor Bar
Pass Problem,
which also is
affected in
response to
torque.

Motor ID
Database
Building
Location
Date/Time

PM 1501 TLA
WORK 2005
Bba contraincendio
BASEMENT
4/14/2011 01:21:31 PM

Tested by
Tested for
Explorer SN#
Test Type

333
Electrical

Voltage and Current Waveforms

Phasor Diagram

Rotor Bar

Torque Ripple

17

Appendix A:
MCA

Diagnosis and
Severity Table for
MCA, used to
assess Electric AC
Motors problems.

18

References:
A New Version of MachineLibrary Multimedia Training Package is Now Available, pp. 66-67, or visit the
MachineLibrary www.bently.com.
Technical Associates Of Charlotte, Vibration Analysis Level II & III

Aknowledgements:
Special thanks to Ing. Alvaro Castillo, BASF of Altamira, for support with the MCA analysis by Baker, all under
the Interplant support of the AISTAC Reliability Committee .
Special thanks to Ing. Carlos Garza, UESystems Regional Manager for Mxico & LA for the chance to take part in
this Conference.
Special thanks to all those M&R Practitioners for sharing knowledge and experience at WU VII

Mr. Carlos Hdz. Conti can be reached at :

carloshconti@yahoo.com
C.Hernande@shell.com
19

Detectando Problemas de Rotor

por medio de

Inspeccin Mecnica de Ultrasonido Estructural

Depto.Mecnico
Mantto. Predictivo y Confiabilidad.
Presenta: Ing. Carlos Hdz. Conti, CMRP

Level II Airborne Ultrasound Certified Analyst. By UESystems

ClearWater Beach, F.L. Mayo 2011 1

Contenido
Maquina.
Problema.
Carta de Diagnstico.
Esquema de Zonas de Falla.
Efectos de Falla.
Tcnica.
Recomendacin Diagnstico
Resultado.
Referencias
Anexo A, MCA & Carta de Diagnstico y Severidad.

TLA ALTAMIRA EN DONDE SE UBICA?

ESTRUCTURA ORGANIZACIONAL & PROCESO

Type

Joint Venture ( Shell-TotalMitsui )

Industry

Oil & Gas

Founded

2004, by Shell-Total-Mitsui

Headquarters Altamira, Tams. MX

Key people

Carlos Barajas (Managing

Director)
Loran Karwacki (Asset manager)
Jair Rojas (Finance Manager)
Carlos Oropeza (Operations
Manger)
Juan M. Hdz (Maintenance
Manager)
Vernica Zavaleta ( HR Manager)
Luis Nez (Commercial &
Proyects Manager)

Products

Natural Gas

Employees

80 (2010)

Website

http://sww.shell.com/
4

Terminal de Importacin de LNG- Activos & Alcance Tcnico.

Berthing basin, including mooring & unloading facilities for LNG
Carriers (Carrier Capacity 70,000 to 200,000 m3)
2 LNG Storage Tanks (net capacity 150,000 m3 each)
Process equipment for vaporization & gas pressurizing;
Seawater Supply System with capacity of up to 30,000 m3/hr
Send Out Facilities into Pemex Pipeline and Altamira V PP
Buildings (Control Room, Administration Building, Warehouse
2010 replacing temporary buildings)
Terminal Capacity (Phase 1): 760 mmscf/d Peak (500mmscfd
base load = 3.75 mtpa)
Potential for Expansion (Phase 2):1,200 mmscf/d Peak
(1070mmscfd base load = 8 mtpa)

Mquina: PM-1501
PM-1501 es un motor elctrico de aprox 450 HPs y gira a 1800 rpm, est acoplado a una bomba
centrfuga bipartida de doble succin, cuya funcin es proveer agua de contra incendio, ste equipo
opera cada semana alrededor de 10 minutos y la ruta se inspecciona cada 3 meses.

Problema:
PM1501, El Anlisis de Espectros de Ultrasonido muestra espectro tpico de Problemas de Barras de
Rotor Flojas/Rotas en el Motor, ntese Frec. Paso de Barras de Rotor @ 102.7 Kcpm y hasta 4
armnicos c/u con Bandas Laterales @ 2XFl. # Barras= 102700 cpm / 1800 rpm = 57.05 barras

Carta de Diagnstico:

Carta de Diagnstico:
Una firma de motor de CA normal debe incluir una respuesta de frecuencia de paso de barra del rotor
(RBPF) . Esta respuesta se produce cuando cada barra del rotor pasa perturbaciones leves en el campo
magntico debido a la trayectoria de la corriente elctrica a travs de la geometra del estator / rotor. Una
RBPF elevada se crea cuando las barras del rotor pasan una interrupcin significativa en estos campos
producida cuando la trayectoria actual se ve alterada o distorsionada de las barras de rotor rotas o
agrietadas, juntas de barra del rotor sueltas o defectuosas, mal soldadas, piezas de fundicin porosas de
barra del rotor, o arcos elctricos a travs de la barra del rotor a travs de las interfaces de anillo.
RBPF se identifica como un mltiplo entero de la velocidad del rotor, y por lo general tienen
bandas laterales espaciadas a 2 veces la frecuencia de lnea elctrica (7200 RPM). Los Problemas de
excentricidad del rotor puede ser indicado por otros (menos dominante) conjuntos de bandas laterales
espaciados a 1 x RPM.
Un Motor de CA puede tener de 35 a 96 barras del rotor, por lo que un espectro de FFT con un
rango de frecuencia suficiente, ser necesario para capturar esta falla. 1x y 2x RBPF ser capturado con
una Fmax de 360000 kcpm con una resolucin de 1600 lneas , y proporcionar suficiente resolucin para
definir
las
bandas
laterales
a
2xFL.
La severidad se evala considerado los cambios en las amplitudes de RBPF a lo largo del tiempo. La
variacin de la amplitud con la carga es comn.

Esquema
de Zonas DE

de Fallas:

10

Efectos
de Fallas:

Cuando analize la falla

de rotor, busque e
identifique zonas con
puntos de
recalentamiento
ennegrecidasazuladas. Compruebe
fisuras con lquidos
penetrantes.

11

Tcnica:
La tcnica de inspeccin usada fue: Inspeccin mecnica de rodamientos, aplicando el mdulo
magntico posicionndolo lo ms cerca de la zona de carga de los rodamientos, frec.@ 25 khz, se
salvan los datos y se descargan al DMS para su posterior seguimiento. ste tipo de problemas
generan un sonido tpico audible y oscilante de vaivn.

Recomendacin Diagnstico:
Aplicando la Teora de Anlisis de Vibraciones al Anlisis de Ultrasonido: En los Problemas de Barras
de Rotor Flojas/Rotas en motores elctricos, su fsica no obedece a friccin impactos, y si no
se ajusta una Fmx. adecuada para captar altas frecuencias en el FFT, pueden pasar
desapercibidos, su severidad est dictada por la cantidad de armnicos, as como de bandas
laterales alrededor de stos, lo anterior es una ventaja del uso del Ultrasonido en Inspecciones
Mecnicas.

Resultado:
Se procedi a elaborar el reporte respectivo, continundose con monitoreo rutinario, ste tipo de
Problemas de Rotor normalmente estn relacionados con problemas de calidad de manufactura, y
dado que no opera continuamente el motor, su evolucin ha sido lenta, pero como actividad predictiva,
sta Falla Potencial en tanto se intensifique se proceder a cambiar el motor el cual ya est en
almacn.
12

Anexo A MCA:
Resultados de MCA practicado a ste mismo motor para corroborar el Problema, ntese el aviso de
advertencia indicando fallas por posibles Barras de Rotor.
Motor ID
Database
Building
Location
Date/Time

PM 1501 TLA
WORK 2005
Bba contraincendio
BASEMENT
4/14/2011 01:21:31 PM
Name Plate
450.00
1785
4160
55.0
1.0
1.0
1324.7
98.5
100.0

Hp
RPM
Volts
Amps
pf (pu)
Nema Derating (pu)
Torque (ft-lb)
Efficiency
Percent Load
Test
% Over Voltage
% Unbalance
% Voltage Dist.
% Current
Ef. Service Factor
Rotor Bar (db)
% Op. Point
% Loss Diff.
% Loss Diff.

Tested by
Tested for
Explorer SN#
Test Type

Value
2.43
0.75
0.57
71.33
0.73
-30.87
0.00
0.00
N/A

Status
GOOD
GOOD
GOOD
GOOD
GOOD
WARNING
GOOD
INDET
INDET

333
Electrical
Measured
326.72
1792.6
4261.3
38.6
0.9
1.0
957.7
96.4
72.6

Caution Level
10.0
2.0
7.0
110.0
1.1
-45.0
20.0
25.0
60.0

Warning Level
20.0
3.5
9.0
120.0
1.2
-36.0
30.0
50.0
24.0
13

Anexo A MCA:
Grficos de Espectro de
Corriente mostrando el
Problema de Paso de
Barras de Rotor, el cual
tambin se ve afectado
en respuesta al torque.

Motor ID
Database
Building
Location
Date/Time

PM 1501 TLA
WORK 2005
Bba contraincendio
BASEMENT
4/14/2011 01:21:31 PM

Tested by
Tested for
Explorer SN#
Test Type

333
Electrical

Voltage and Current Waveforms

Phasor Diagram

Rotor Bar

Torque Ripple

14

Anexo A MCA:
Tabla de Diagnstico y
Severidad para MCA,
usada para evaluar
Problemas
Elctricos
de Motores de CA

15

Referencias:
A New Version of MachineLibrary Multimedia Training Package is Now Available, pp. 66-67, or visit the
MachineLibrary www.bently.com.
Technical Associates Of Charlotte, Vibration Analysis Level II & III

Mr. Carlos Hdz. Conti can be reached at :

carloshconti@yahoo.com
C.Hernande@shell.com
16